Aung Kyaw phyo Instrumentation and Control System Assignment (1)

HND20001E 1st Attempt

Unit No. 16
Title: Instrumentation and Control System

Pearson BTEC Level 5 Higher National Diploma IN Engineering

Assignment 1(1st Attempt)

Assessor: Dr. Rosen

Student; Aung Kyaw phyo

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Aung Kyaw phyo Instrumentation and Control System Assignment (1)

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Content
Part Page

Working Principle of Oxygen Concentrator 3

Instruments used in control system 4

Sensors and Transducers 4-7

Signal conversion 7-10

Signal conditioning 10-14

The importance of process control system 14-15

Process controller terminology used in 15-18

industrial applications
Reference 18

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1. Working Principle of Oxygen Concentrator

Oxygen concentrator block diagram

Figure reference - https://pdf.medicalexpo.com/pdf/honeywell/honeywell-sensing-medical-
solutions-oxygen-concentrators/78321-234896-_2.html

Gauge pressure sensor

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Oxygen sensor

Magnetic sensor

An oxygen concentrator receives air, purifies it and then distributes the newly formed air.
Typically, air is composed of 80% nitrogen and 20% oxygen. An oxygen concentrator increases
the oxygen content to over 90%. Sieve bed filters contain Zeolite which removes the nitrogen
from the air. Oxygen concentrators are used to assist patients with respiratory illness or lung
disease, who have difficulties in absorbing oxygen into bloodstream. Oxygen concentrators can
be used in hospitals, home and some devices are portable.
2. Instruments used in control system are-compressor, motor, heat changer, tanks, motor,
muffler, electronic control circuit, molecular sieves, four-way solenoid valve, cross over
valve, pressure reducing orifices, pressure regulators, gauge pressure sensor, oxygen
sensor, magnetic sensor and flow meter adjustment valve.
3. Sensors- the devices which can sense the change in the surroundings, for instance-
pressure, sound, displacement, light, temperature etc. and offer the output for users to
read the format in an easy way.
Transducers-the devices that will convert from one physical to another meaning. Although they
can measure similar qualities to sensors, their input and output signals are not tha same each
other. Sometimes, they are mentioned to energy converters.
Gauge pressure sensor
Gauge pressure sensor is silicon pressure sensor made to measure the pressure of gases and
liquids. Pressure is a statement of the force that is necessary to stop a fluid from splashing out
and is usually described in terms of force per unit area. A gauge pressure sensor usually takes
action to a transducer that inspires a signal as a role of the pressure imposed.

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Figure reference- https://eu.mouser.com/new/honeywell/honeywell-abp-pressure-sensors/

Measurement type gauge
Pressure range 0 to 100 psi
Maximum pressure(x rated pressure) 245 psi
Supply voltage(V) 5(typ)
Supply current(mA) or Excitation Current 0.6 (typ)
Output type Analog
Full scale output(mV) 5.83(min), 6.36(max)
Operation temperature Range(°C) -40 to 125
Temperature compensated Yes
Compensated temperature Range(°C) 0 to32
Vibration at 20 to2000Hz (g rms) 15 g at10 Hz to 2kHz
Shock (g) 100
Shock duration (ms) 6
Life (cycles) 1 million cycles(min)
Package style DIP
Accuracy 0.25
Resolution 12 bit
The measurement type of sensor is gauge and it is pressure sensor. Its pressure range is 0 to
100(Psi) pounds per square inch and maximum is 245 Psi. If an output is gotten, it will be analog
type. Operation temperature range is -40 to 125°C.

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Oxygen sensor
Oxygen sensors are created to measure the quantity of oxygen in the air. Oxygen sensors can
typically measure between 0.01-25% oxygen and it can be also used for monitoring oxygen
depletion. Some special oxygen sensors can measure 0-100% oxygen.

Figure reference- https://www.aliexpress.com/item/1595755577.html?

aff_fcid=ca1ecc97774748a6bcbb70e9e302e3ae-1628661949927-05833-
_dYkk1qz&aff_fsk=_dYkk1qz&aff_platform=link-c-
tool&sk=_dYkk1qz&aff_trace_key=ca1ecc97774748a6bcbb70e9e302e3ae-1628661949927-
05833-_dYkk1qz&terminal_id=69eb32cd74a343d49f3d85c4a8f7c735&tmLog=new_Detail
Measurement range 20.8%-96.0%( O2/N2 dry mixed gas)
Measurement accuracy ±2%
Repeatability Less than ±1% FS
Resolution 0.1% O2 increments
Ambient Temperature 5~45°C
Response Time t90 Less than 30 seconds
Sample Gas Pressure 0~20 kPa
Sample Gas Temperature 5~45°C
Sensor type is vacuum sensor and the output is digital. It can measure 0-96% oxygen.
Supply voltage is DC 5V±0.5V and supply current is less than 60mA.

Magnetic sensor

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Magnetic sensor can control motor and sense motor speed. Those magnetic position sensors are
created to provide reliable, highly accurate output for smooth motor control.

Figure reference- https://uk.rs-online.com/web/p/motion-sensor-ics/1909743/?cm_mmc=UK-

PLA-DS3A-_-google-_-PLA_UK_EN_Semiconductors_Whoop-_-Motion+Sensor+ICs_Whoop-
_-1909743&matchtype=&pla-
302651754894&gclid=EAIaIQobChMImcqW3ryo8gIVOYBQBh1j2wEUEAsYBiABEgKatfD_
BwE&gclsrc=aw.ds
Sensor type Hall effect sensors

Mounting type Through hole

Maximum operating supply voltage 24 V

Minimum operating supply voltage 4V

Pin count 4

Maximum operating temperature +150 °C

Minimum Operating Temperature -40 °C

Resolution 13 bit

Sensing range 0°to 180°

It is 4-pin quadrature and open collector outputs. Its operating temperature range is 40°C to
150°C.

4. Signal conversion
The device which can convert signals from sensors to industrial current signals and analog
input signals to output signals, normal signals or isolates signals is called signal conversion is
defined as a signal converter. They are analog-to-digital converters (ADCs), digital-to-analog

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converters (DACs), voltage converters, frequency converters or translators, current-to-voltage

converters, voltage-to-frequency converters, charge converters and current loop converters.
Resolution is a central element in signal converters. The better the resolution, the more accurate
the data will be provided by the converter.
4-20 mA Current Loop
The 4 to 20mA current loop is a very robust sensor signaling standard. Current loops are ideal for
data transmission. All the signaling current flows through all components; the same current flows
even if the wire terminations are less than perfect. All the components in the loop drop voltage
due to the signaling current flowing through them. The signaling current is not affected as long
as the power supply voltage is greater than the sum of the voltage drops around the loop at the
maximum signaling current of 20mA.

Figure 1: Basic Current Loop Schematic

Figure 1 shows a schematic of the simplest 4-20mA current loop.
There are four components,
1. ADC power supply
2. A 2-wire transmitter
3. A receiver resistor that converts the current signal to a voltage and
4. The wire that interconnects it all.
Two Rewires exist since you have a wire out to the sensors and another back. Current supplied
from the power supply flows through the wire to the transmitter. The transmitter regulates the
current flow. The transmitter only allows a current proportional to the measured parameter to
flow, called the loop current. The current flows back to the controller through the wire. The loop
current flows through Receiver to ground and returns to the power supply. The current flowing

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through Receiver produces a voltage that is easily measured by an analog input. For a 250Ω
resistor the voltage will be 1 VDC at 4 mA and 5 VDC at 20mA.
Analog to digital converter
An A/D converter converts analog signals into binary words.

In analog to digital conversion, there are 2 step process,

Quantizing- breaking down analog value is a set of finite states
Encoding- assigning a digital word or number to each state and matching it to the input signal
Step 1- Quantizing
For example- we have 0-10V signals. We need to separate into a set of discrete states with 1.25V
increments.

How we get1.25V?
The number of possible states that the converter can output is N=2n,

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where, n is the number of bits in the A/D converter.

Example, for a 3 bit A/D converter, N=23=8.
Analog quantization size, Q= (Vmax –Vmin)/N = (10V-0V)/8= 1.25V

Encoding
Here we assign the digital value (binary number) to each state for the computer to read.

Accuracy of A/D conversion

There are two ways to best improve accuracy of A/D conversion;
increasing the resolution which improve the accuracy in measuring the amplitude of the analog
signal and
increasing the sampling rate which increases the maximum frequency that can be measured.
Resolution
Resolution (number of discrete valves the converter can produce) = Analog Quantization size(Q)
(Q)= V range/ 2n, where V range is the range of analog voltages which can be represented.
Limited by signal-to-noise ratio (should be around 6dB)
In our previous example; Q= 1.25V, this is a high resolution. A lower resolution would be if we
used to a2-bite converter, then the resolution would be 10/2n = 2.50V.
Sampling rate

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Frequency at which ADC evaluates analog signal. As we see in the second picture, evaluating
the signal more often more accurately depicts the ADC signal.
Aliasing
Occurs when the input signal is charging much faster than the sample rate.
For example, a 2 kHz sine wave being sampled at 1.5 kHz would be reconstructed as a 500 Hz
(the aliased signal) sine wave.
NY Quist Rule,
Use a sampling frequency at least twice as high as the maximum frequency in the signal to avoid
aliasing.
Overall Better Accuracy
Increasing both tha sampling rate and the resolution you can obtain better accuracy in AD
signals.
Resolution= 2.50V Resolution= 1.25V
Sampling rate= 1Hz Sampling rate= 2Hz

Figure reference-
https://www.academia.edu/16236295/ADC_Analog_to_Digital_Converter_Microkontroller
Signal conditioning

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Signal conditioning circuits are used to process the output signal from sensors of a measurement
system to be suitable for the next stage of operation.

Figure reference- https://www.youtube.com/watch?v=HSHJXXFigz8

Types of signal conditioning are Amplification, Excitation, Bridge completion, Filtering,
Attenuation, Isolation, Linearization and Compensation.
Amplification- the process that is ordered to increase the input signal to better the suit of DAQ
normally using an amplifier is called amplification. Amplification also can improve the
sensitivity and resolution of the measurement.

Figure reference-  Microsoft Teams. 2021. Join conversation. [online]

Filtering -a filter is a circuit that removes selected frequencies from the signal. Filtering is most
often performed to remove unwanted signals and noise from the data. There are 5 types of filters,
Low pass, High pass, Band pass, Band stop and All pass.

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1. Low pass
2. High pass
3. Band pass
4. Band stop

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5. All pass

Isolating- isolated signal conditioning products protect and preserve valuable measurements and
control signals, as well as equipment, from the dangerous and degrading effects of noise,
transient power surges, internal ground loops, and other hazards present in industrial
environments. Isolation requires signals to be transmitted across an isolation barrier without any
direct electrical contact. Light-emitting diodes (LEDs), capacitors and inductors are three
commonly available components that allows electrical signal transmission without any direct
contact. The principles on which based from the core of the three most common technologies for
isolation-
1. Optical
2. Capacitive
3. Inductive coupling

Optical isolation Capacitive isolation

Inductive coupling isolation

Figure reference-https://www.google.com/amp/s/slideplayer.com/amp/10652626/

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5. The importance of process control systems

Process control refers to the methods that are used to control process variable when
manufacturing a product. for examples, factors such as the proportion of one ingredient to
another, the temperature of the materials, how well the ingredients are mixed, and the pressure
under which the materials are held can significantly impact the quality of an end product.
There are 7 signs why process control system is important.
1. Quality

2. Safety

3. Consistency

4. Optimization

5. Efficiency

6. Cost

7. Environmental

Quality is a degree or standard of excellence, especially a high standard which is hardly a useful
explanation. In this process, the higher the quality of oxygen concentrators, the better for the
patients. So, in oxygen concentrating plants, each one thing that includes in oxygen concentrators
should be in good or the best quality. The sensors that can replace in oxygen concentrators also
must be in satisfied quality for patient. There is a proverb in engineering fields ‘safety first’. We
have to use Time Proven PSA (pressure swing absorption) technology to separate the oxygen
from the air directly. We also should not split charging during shipment which decreases the
safety risks. Issuing alarm have to be put against abnormal parameters. The good quality product
is nothing without safety. Safety is needed in everywhere. So we have to use the one that have
WHO (World Health Organization)-recognized certification. The most important parts in this
plant is to ensure consistency. Using the proper process control instrumentation for remodeling
and reworking internal operations allows our machines to reduce variability and run them as well
as they can. There will be more apace and time for business to grow by eliminating unnecessary
machinery or even physical labor simply. So, it can reduce labor costs. Energy savings, improved
safety, consistent product quality, lower manufacturing cost, improved environmental
performance are the main benefits of efficient process control in oxygen concentrating plants.
For maintenance, biomedical engineering staff and service contract with the manufacturer or
third-party organization must be included in oxygen concentrator. If we are complete with the
facts that I have been described, environment of uses will be automatically increased. For

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example, if our product has high quality and consistency, safety and best efficiency, it will be
satisfied for the patients who are in home, hospital and nursing home with best performances. So,
we can be the one and only best production in environment. That’s why process control system is
very important in oxygen concentrating processes.

6. Process controller terminology used in industrial applications

Set-point- the water level that is trying to keep for restoration in the optical.
Process variable- the current measured gain of a specific part of a process that is controlled or
monitored
Deviation- the difference between the set-point and the process variable
Gain- the charge amount in input divided by thr charge amount in output. A process which has
high gain will respond more to the controller changing output.
Proportional control
A type of control where the output strength is transformed according to the difference between
the current measure the set-point is called a proportional control. In the control system, the
control effort is proportional to the error. The greater the error, the greater the effort. The
manipulated variable is continually adjusted by a proportional controller. Proportional control is
used where maintaining a process variable to a tighter tolerance and timely responsiveness are
required.
ea(t) ∝ e(t)
ea(t) = Kp ea(t), Kp = proportional controller gains or proportional constant between error and
controller output (%)
taking Laplace transform
Ea(s)= Kp E(s)
Transfer function= output/ input
Ea(s)/ E(s)= Kp

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Figure -1

Integral control
A type of control where the output strength is transformed according to all the difference from
the set-point that have been catalogued since the beginning of a process is called an integral
control.

ea(t) ∝ ∫ e(t )

ea(t) = Kl ∫ e(t )Kl = integral constant

Figure-2
Integral measures the area between the error values and the time axis. If the error doesn't return
to zero, the area of the error gets larger and larger. Figure 2 shows how the integral output can
react to this kind of trend. As the area between the error curve and the time axis increases, the
output increases proportional to this area. As a result, the output drives the actuator harder and
harder to correct the error.

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Figure-3

Derivative control
Derivative control mode is sometimes called Rate, as it produces an output based on the rate of
change of the error.
ea(t) ∝ e(t)/dt
ea(t) = KDde(t)/dt
KD= Derivative constant

Figure- 4
Derivative mode produces more control action if the error changes at a faster rate. If there is no
change in the error, the derivative action is zero. Derivative mode has an adjustable setting called
Derivative Time (Td). The larger the derivative time setting, the more derivative action is
produced. If the derivative time is set too long, oscillations will occur and the control loop will
run unstable. Derivative control mode can make control loop respond a little faster than with PI
control alone.

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Figure-5 Figure-6
References

(Honeywell Sensing - Medical Solutions for Oxygen Concentrators - Honeywell Advanced Sensing
Technologies - Page - PDF Catalogs | Technical Documentation, 2021)

(ABP Amplified Basic Pressure Sensors - Honeywell | Mouser, 2021)

(VM821Q1 Honeywell, Hall Effect Sensors, 4-Pin SIP | RS Components, 2021)

(Global Online Shopping for Apparel, Phones, Computers, Electronics, Fashion and more on AliExpress,
2021)

18, f., 2021. ADC (Analog to Digital Converter) Microcontroller. [online] Academia.edu. Available at:
<https://www.academia.edu/16236295/ADC_Analog_to_Digital_Converter_Microkontroller> [Accessed
17 August 2021].

Youtube.com. 2021. [online] Available at: <https://www.youtube.com/watch?v=HSHJXXFigz8>

[Accessed 17 August 2021].

(Signal conditioning Noisy. Key Functions of Signal Conditioning: Amplification Filter, Attenuation,
Isolation, Linearization. - ppt download, 2021)ument

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